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IND-04 · Automotive EV InterconnectAutomotive EV
Automotive EV
Interconnect.
Traction, BMS, charging, and infotainment harnesses for EV and hybrid OEMs and Tier-1 suppliers. IATF 16949 PPAP Level 3, USCAR-2 connector qualification, 800V pack interconnect with HVIL safety. Drawing-driven from NPI through volume.
[IND / AUTOMOTIVE]
Quality systemIATF 16949
PPAPLevel 1-5
VoltageUp to 1000VDC
USCAR-2Class V qualified
Procurement Friction · WHERE_IT_SLIPS
Where most automotive ev programs slip.
PAIN-0101
USCAR-2 vibration failure
Engine-bay sensor connector passes USCAR-2 ambient continuity but fails the V3 sealing class after 200h vibration — root cause is wrong TPA orientation at assembly.
PAIN-0202
HVIL loop open under thermal
High-voltage interlock loop fails at -40°C cold-soak because the auxiliary signal pin crimp barrel shrank and lost contact at the pin shoulder.
PAIN-0303
BMS slave wiring length variance
Cell-tap wire length varies ±5mm between assemblies on the same lot, causing voltage measurement error during high-current discharge that trips BMS fault.
PAIN-0404
IMDS rejection at PPAP
IMDS submission rejected because the wire jacket pigment lot contains 0.12% lead — OEM threshold is 0.10%, supplier never re-verified after pigment vendor change.
Capability Stack · WHY_VEINWIRE
Where we move the dial.
F-0101
IATF 16949 supply chain
Tier-1 OEM audited supply chain with capability study, control plan, FMEA, and PPAP Level 3 documentation standard.
F-0202
USCAR-2 qualified connectors
Aptiv, TE, Yazaki, Sumitomo, JST connector inventory pre-qualified to USCAR-2 sealing classes S0 through V3.
F-0303
HV traction stock
Orange-jacket UL 758 EV wire 20 AWG through 2/0 AWG. ISO 6722 / JASO D 624 / LV 216 compliant variants.
F-0404
Hipot 100% at 1500VAC
Every high-voltage assembly tested at 1500VAC for 1 second. Pass/fail logged to ERP with operator badge and timestamp.
F-0505
IMDS / CMRT submission
Full material declaration in IMDS, conflict-minerals report per OECD due diligence. Pigment lot tracking for trace-metal compliance.
F-0606
BMS slave precision build
Cell-tap wire length controlled to ±1mm per harness via dedicated CNC cutting and form-board verification.
Spec Table · TECH_PARAMS
Build envelope.
| Quality system | IATF 16949:2016 audited supply chain. PPAP Level 1-5 per AIAG manual. |
|---|---|
| HV voltage | 30VDC to 1000VDC continuous. 1500VAC hipot test per LV 123 / SAE J1742. |
| HV wire | Orange-jacket UL 758, ISO 6722 Class B/C/D, JASO D 624, LV 216, USCAR-21 high-voltage. |
| LV wire | TXL, GXL, SXL per SAE J1128. Cross-linked polyethylene, halogen-free option. |
| Connector families | Aptiv Megafit HVE, TE HVA280, Yazaki YESC, Sumitomo HX, JST GH/SH, Molex MX150. |
| Sealing | USCAR-2 S0 through V3 (vibration with sealed). IP67 / IP69K available. |
| Temperature | -40°C to +125°C standard. -40°C to +155°C with cross-linked ETFE jacket. |
| Termination | Hex-crimp lugs M5/M6/M8/M10, ultrasonic weld for aluminum termination, mechanical lug for service-disconnect. |
| Workmanship | IPC/WHMA-A-620 Class 2 or Class 3 plus IATF 16949 PPAP Level 3 standard. |
| Documentation | PPAP package, IMDS submission, CMRT, dimensional report, capability study, control plan, PFMEA. |
Fab Protocol · BUILD_PIPELINE
From PO to ship.
PR-0101
PPAP scope review
Customer PPAP level (1-5), USCAR sealing class, OEM-specific drawing format reviewed at NPI kickoff.
PR-0202
BOM lockdown
Connector, wire, terminal, seal vendors locked at PPAP submission. No substitution without OEM-approved deviation.
PR-0303
Capability study
Crimp force, pull strength, dimensional Cpk run on 30-piece sample. Target Cpk ≥ 1.67 per AIAG Capability Study standard.
PR-0404
Class-3 assembly
Torque-controlled crimping per Aptiv/TE/Yazaki tooling spec. TPA orientation verified per first article.
PR-0505
100% test
HV: hipot 1500VAC + continuity. LV: continuity per circuit. USCAR-2 sealing on sample lot per AQL 1.0.
PR-0606
PPAP submission
Level 3 PPAP package: dimensional, IMDS, CMRT, control plan, PFMEA, capability study, FAI per AS9102 or AIAG template.
Use Cases · APPLICATIONS
Where this ships.
800V traction harness
Pack-to-inverter main power with Aptiv Megafit HVE or TE HVA280 connectors and HVIL interlock signal.
BMS cell-tap interconnect
Precision-cut cell-tap wiring (±1mm length tolerance) for prismatic and pouch battery modules.
DC fast-charge inlet
CCS Combo, CHAdeMO, NACS, GB/T charging inlet harness with thermistor and HVIL monitoring.
Onboard charger harness
AC input to OBC harness with EMI filtering and ground-fault detection per SAE J1772.
12V infotainment harness
Cabin audio, navigation, ADAS camera harness with TXL/GXL wire and USCAR-2 connectors.
Auxiliary motor wiring
Compressor, pump, fan motor wiring for thermal management system on EV platforms.
The PPAP-killer we see most often is IMDS rejection on the wire jacket — pigment lot drift pushes lead content from 0.08% to 0.12% and the OEM threshold is 0.10%. The supplier never re-verified after the pigment vendor changed mid-year. We hold IMDS material declaration as a per-lot control, not a one-time submission. Every wire reel arriving gets the pigment lot logged, and IMDS is updated if the lot changes. That single discipline eliminates the most expensive PPAP failure in EV harness work.
FAQ · SPEC_QUERIES
Procurement questions.
Are you IATF 16949 certified?+
Yes — IATF 16949:2016 audited supply chain with current valid registration. Tier-1 OEM PPAP submissions supported through Level 5. Customer audit access available under NDA. Internal audit log, CAPA system, and management review records on file.
What is your highest voltage qualification?+
1000VDC continuous, 1500VAC hipot tested 100%. Aligned to LV 123 (VW Group), SAE J1742, ISO 6722 Class D high-voltage requirements. Connectors from Aptiv Megafit HVE, TE HVA280, JAE MX44 are standard for 800V pack interconnect programs.
Do you handle BMS cell-tap precision builds?+
Yes. Cell-tap wire length controlled to ±1mm per harness using dedicated CNC cutting station and form-board verification. Connector terminations qualified for BMS slave board sense voltage accuracy under 200A discharge conditions.
Can you submit IMDS material declarations?+
Yes — full IMDS submission per OEM (VW Group, BMW, Mercedes, Stellantis, Ford, GM, Tesla template). Conflict-minerals report (CMRT) per OECD due diligence. Pigment, plating, and resin lots tracked per shipment for trace-metal compliance.
What sealing class can you qualify connectors to?+
USCAR-2 sealing classes S0 (unsealed) through V3 (vibration + sealed + immersion). Engine-bay assemblies typically run V3 with 200h vibration + 1m immersion. Cabin assemblies run S2-S3. Test reports available per program.
Sibling specs
Industries served
Capability deep-dives
Engage · RFQ_INTAKE
Quote your automotive ev program.
Drop drawings, BOM, or rough concept. Engineering reviews within 4 business hours. NDA available on request.
Back to Industries hubEngage · CTA_002
Quote your EV interconnect program.
Send voltage class, PPAP level, OEM target, USCAR sealing class. PPAP-ready quote within 4 business hours. Response within 4 business hours. No obligation. Drawings stay under NDA.